AU7329681A - Improved multi-purpose zone controlled blast furnace and method of producing hot metal, gases and slags - Google Patents

Description

IMPROVED MULTI-PURPOSE ZONE CONTROLLED BLAST

FURNACE AND METHOD OF PRODUCING HOT METAL, GASES, AND SLAGS

TECHNICAL FIELD This Invention relates to blast furnaces and their methods of operation and, more particularly; to blast furnaces used to produce hot metal products or reducing gases.

BACKGROUND OF THE INVENTION This Invention describes how the modern blast furnace can be modified and operated so that both the long sought goal of finding an economic method of eliminating the wasteful of coke "solution loss" reaction and the urgent present goals of eliminating the use of oil and natural gas in blast furnaces and In many other Industrial processes can be realized. Improved zone controlled multi-purpose blast furnaces will, at the option of the operators, become either higher than conventional hot metal producers (M8F)s or high made to specifications gases producers (GBF)s. In either case the temperature, volume and composition of the ascending gas stream is modified and regulated by i ntroduci ng or withdrawing gas through auxiliary tuyeres located in the side of the furnace, as required to improve its ability to perform the critical manufacturing process operations occurlng in each blast furnace zone. "Solution loss", the Boudouard reaction, is avoided in MBF operations to reduce coke consumption and fully employed in GBF operations to produce a low cost multi-purpose gas (MG) free of CO₂ and S gases and containing large amounts of CO formed from less expensive sources such as non-coking coals, top gases and steam.

.A portion of the gases co-generated in the GBF operation is continuously removed through the side of the furnace above the bosh after being temperature regulated, without incurring CO₂ or S gases contamination; by endotherml reacting gas injections made through a set of auxiliary tuyeres located below the top of the bosh. The temperature of the low cost to produce gas withdrawn here from a portion of the stock where the gas found is substantially free of CO₂, H₂O and S gases and is composed of CO, H₂ and N₂ is precisely regulated. It makes an ideal reducing gas for use in MBFs because its temperature can be closely regulated to just below 1000° and CO:H₂ ratio can be maintained at approximately 6:1. It also has a Btu content between 200 and 280 which makes it a highly efficient utility boiler fuel equivalent or superior to natural gas (see Exhibit 3). Gas flows are regulated on the basis of Information obtained from on-line samples and perfomance-impairing recycling alkali metals and zinc may be purged while in a volatile form.

BRIEF DESCRIPTION OF THE INVENTION This Invention employs improved zone controlled multipurpose blast furnaces which are modern blast furnaces to which have been added strategically placed auxiliary tuyeres, gas conveying conduit means and controlling equipment. These can be operated optimally In either a high hot metal production MBF mode or high specification gases production GBF mode.

A method of controlling MBFs having three zones, zone I being in front of the primary tuyeres, zone 2 being the balance of the bosh extending from the crucible to the mantle, and zone 3 extending above the mantle comprises:

(a) introducing into the top of the furnace a solid charge containing an amount of iron oxide sufficient to achieve a metallic oxide/coke ratio of approximately twice conventional, flux constituents sufficient to form a S controlling slag, and only enough coke to provide in zone 1 and 2 a carbonaceous grate and the major source of high temperature heat above 1000°C, from about 460 to 570 pounds. (b) burning coke in said charge in zone 1 preferably with a blast enriched with approximately 1 to 3% O₂ to produce a high temperature gas employed to melt iron and slag in zone 2 and to provide an upwardly moving gas stream whose temperature decreases to about 1000°C at the top of zone 2; (c) introducing a controlled flow of reducing gas at a temperature of about 1000°C through tuyere sets 2 and 3 near the mantle at the bottom of zone 3 sufficient to maintain a heat and chemical reserve adequate to insure reduction of metal oxides without "solution loss" caused by iron oxide reduction and that the burden is heated to approximately 1000°C as it reaches the bottom of zone 3, said gas containing CO₁H₂, and N₂ and providing at least about one-half of the CO and H₂ that passes upwardly into-zone 3 to reduce the. iron oxide to iron;

(d) controlling the introduction of said reducing gas to malntaln a H₂:CO ratio of at least about 1:6 in said upwardly moving gas near the bottom of zone 3;

(e) withdrawing molten metal and molten slag from near the bottom of the furnace; and (f) withdrawing gas from the top of said furnace having a heat content of from about 100 to about 155 Btu per cubic foot.

In the GBF mode of operation, three zones, zone 1 being in front of the primary tuyeres, zone 2 including the balance of the bosh extending from the crucible to the mantle, and zone 3 extending above the mantle, are operated so as to co-generate two made to specification gases by:

(a) introducing a charge containing solid carbonaceous matter other than coke and slag producing material near the top of the furnace; (b) burning the solid carbonaceous material portion remaining when the charge reaches zone 1 to melt slag in zone 2 and to provide heat for the endothermic reactions of step (c);

(c) introducing a CO₂ and H₂O containing gas into the furnace through tuyeres below the mantle to endothermically react with carbon at a temperature over about 1000°C to produce CO and H₂;

(d) regulating the input to maintain the temperature of the gas near the bottom of zone 3 at about 1000°C;

(e) withdrawing gas from tuyeres located near the bottom of zone 3 and above the mantle, said gas having a Btu content per cubic foot of at least 200, containing CO, H₂ and N₂ and being substantially free of CO₂, H₂O and sulfur;

(f) removing molten metal and molten slag from near the bottom of the furnace; and

(g) removing a gas from near the top of said furnace produced by pyrolysts and volatilization in zone 3 which contains hydrocarbons,

CO, CO₂, H₂, H₂O, N₂ and sulfur compounds. in particuiari ly preferred embodiments of this invention, the blast furnace has a primary set of tuyeres (for combustion in zone 1), a second set of tuyeres (set 2) near the top of zone 2 below the mantle and two sets of tuyeres (sets 3 and 4) near the bottom of zone 3. The double set of tuyeres near the bottom of zone 3 (that is, near the bottom of the shaft but above the mantle) provides advantages in both MBF and GBF modes of operation. Tuyere set 3 will be positioned just above the mantle and tuyere set 4, If used, desirably is located as close to tuyere set 3 as practicable.

In another preferred embodiment, a zone controlled blast furnace operated in the MBF mode and another zone controlled blast furnace operated in the GBF mode form part of a single system with the GBF furnace supplying reducing gas to the MBF furnace in sufficient quantities so that enough CO is introduced into zone 3 to maintain a CO:CO + CO₂ ratio throughout zone 3 that favors reduction of iron oxide and substantially avoids solution loss. The required CO:CO + CO₂ ratio varies with temperature as shown for instance in Fig. 41 (p. 195) of Gumz "Gas Producers and Blast Furnaces", Wiley and Sons, N.Y. (1950). That figure sets forth the ratio of CO:CO + CO₂ needed to favor the reaction, FeO + CO = Fe + CO₂ as a function of temperature. Desirably the ratio is maintained at least 10% above the minimum shown in Fig. 41 of the Gumz text.

In the practice of this invention a substantial portion of the metal oxide is reduced to metal by CO in the upper portion of zone 3 and the remainder is reduced, primarily by reaction with hydrogen, in the lower portion of zone 3. In MBF operation the coke in zone 1 is consumed with a high temperature blast to produce a high temperature gas volume. The temperature and volume of gas are just sufficient to allow the gas, while moving evenly up through zone 2, to transmit to the slag and HM found there its sensible heat above 1000°C to consistently attain specification temperatures and to control sulfur. No endothermic reacting inputs such as oil or natural gas need be injected into zone 1. Specification temperature hot metal and slag are withdrawn near the bottom of the furnace and often will have a temperature of from about 1600°C to about 1700ºC. A gas, with an improved Btu content of 100 to 155 Btu per cubic foot, is withdrawn from the top of the furnace.

By minimizing, in MBF mode operations, certain conventional practice problems, favorable chain reactions can be instigated. For example, at high operating levels it is difficult to push the gases generated near the bottom up through the counterflow of molten materials in the bosh. The gas flow through a cross section tends to be uneven, with the volume, temperature and velocity being highest toward the center. High temperature gases escape upward before they can transmit enough of their high temperature heat, and the "solution loss" reaction is aggravated. In MBF practice normally over one-half of the CO and H₂ reducing gas content will be introduced through the sides and evenly distributed above where there is a counter flow problem. Even though THM/Hr (tons of hot metal/hour) will increase approximately 50%, the combination of a minimum coke charge, an Increased 0₂ content In the blast and no controllable zone 1 endothermlc reactions can result in approximately a 25% reduction in the volume of gas per minute moving up out of zone 2 and a decrease in the slag moving down. The composite result is a large decrease in coke rate, achieved without injecting any amount of oil or natural gas by largely eliminating "solution loss" and by reducing other energy requirements. A large increase in THM/Hr, an improved Btu content top gas, and a more controlled operation measurable In terms of both HM and slag quality and uniformity is also obtained, making the latter a product which can be processed directly into rockwool or synthetic-igneous rock castings. in the gas producing (GBF) mode of operation: Conventional oxidation and reduction reactions, an oxygen enriched blast, and the Boudouard reaction are employed to efficiently consume in zones 1 and 2 the char resulting from a solid carbonaceous charge composed of such low cost materials as low grade co.al, lignite, industrial and domestic carbon-containing waste products, including, for example, paper, plastics, rubber or the like. No coke is charged. Gaseous endothermic reacting materials containing CO₂ such as process top gases, for example MBF basi-e oxygen steel or OR process off gases, are injected below the mantle through tuyere set 2, and also at the primary tuyeres if desired. These gases react above 1000°C with carbon to produce the desired reducing gas constituents CO and H₂ and to regulate the temperature and the chemical content of the multipurpose gas (MG) , withdrawn above the mantle through tuyere set 3, at approximately 1000°C, and that withdrawn through set 4 at a lower temperature.

Activities in GBF zone 3 above tuyere set 4 are regulated by the volume of gas generated in zones 1 and 2 which is aI lowed to progress to the top of the stack. The amount will vary according to the added 0₂ content in the bosh. The pyrolysis activity in zone 3 above tuyere set 4, produces synprodsgas (synthetic products gas), composed of CH. and other hydrocarbons, CO, CO₂, H₂, H₂O, N₂ and S compounds, which is withdrawn at the top.

When the GBF charge optimally contains iron oxide, molten iron will be withdrawn from the bottom of the furnace. The gas, which is suitable for use as a reducing gas, boiler fuel, or the like, will be withdrawn through the side above the mantle. Slag will be withdrawn from near the bottom.

Molten made to specification slags produced in either mode of operation can be transported to other production units within zone controlled blast furnace systems where they can be blown, or spun, or cast into commercial products or formed into cement clinker, as is or after incorporating additions of powdered materials. The specification top gas produced in the MBF mode will be consumed as is or after being improved by blending with MG to the extent required to produce a gas with a Btu content of at least about 155 and with an ecologfcally acceptable sulfur content. The specification gases produced in the GBF mode will be MG, optionally withdrawn at two different temperatures through tuyere sets 3 and 4, and synprodsgas, which may be further processed, preferably within the system, to produce SCOG (synthetic coke oven gas) employing the same techniques used in processing raw effluent slot coke oven gas and/or a wide variety of other products including plastics, fertilizers, chemicals, fuels, man made fertilizers and fibers, etc.

The above and other aspects of this invention are based, Interalia, on one or more of the following recognitions and/or discoveries:

D.1 It is undesirable for economic and other reasons at this time to consume oil and natural gas in blast furnaces; to desulphurize HM outside the blast furnace; to use metal ized burden materials reduced in other process (e.g. DR2); to rapidly consume the available supply of high grade coking coals; or to spend large amounts of money merely to capture and not advantageously consume pollutants.

D.2. "Solution loss" has in the past been reduced,but without significantly lowering the overall cost of energy/THM. The high level of zone control in MBF or GBF operation can produce maximum gains by both avoiding and fully employing, according to the mode of operation, the Boudouard reaction in consuming diversified energy sources. D.3 Improved zone controlled blast furnaces, with four sets of tuyeres used to input and output precisely controlled gaseous flows, can produce a maximum amount of high quality hot metal (HM) using a minimum amount of coke when operated in the MBF mode; or, alternatively, can produce a maximum volume of quality specification gases and slags (gases and slags made to comply with chemical and/or temperature specifications) useful in the manufacture of electrical energy, plastic products and man-made fertilizers, fibers, building materials, chemicals and cement, when operated in the GBF mode. The alternate GBF mode uses maximum amounts of low cost raw materials and no coke.

D.4 Tuyere set 4 located in the lower part of zone 3 above tuyere set 3 can, on improved zone controlled blast furnaces, provide the sampling access to the furnace atmosphere in this critical area needed to provide, along with other input and output information, the basis for precise, preferably automated adjustments. These will, when operating in the MBF mode, be made by regulating the gaseous inputs into tuyere sets 1, 2, and 3 and in the GBF mode into tuyere sets 1 and 2 to immediately effect precise changes which in conventional practice would require hours or be impossible. Readily available conventional combinations of electrical, hydraulic and pneumatic controls and valves normally used in advanced gas flow system will be employed.

D.5 When economically operating in the MBF mode, to save coke by largely eliminating, "solution loss", it is desirable to generate outside the furnace from low cost raw materials a larger amount of reducing gas than is generated inside; to deliver the reducing gas at a controlled temperature at the bottom of zone 3 to provide both a heat reserve just above tuyere set 3 and a chemical reserve extending to the top of the stack; to improve the quality of the top gas produced to the extent it becomes a desirable specification product having, at least about 100 Btu per cubic foot; to employ a reducing gas which is substantially free of CO₂, H₂O and S compounds and has a desirable H₂:CO ratio; to maintain throughout zone 3 equilibrium concentrations of CO:CO₂ and H₂:H₂O conducive to oxide reduction without substantial "solution loss"; and to maintain the lower portion of zone 3 at a temperature very close to but not over about 1000°C. Some of these practices will achieve other zone control results such as maintaining the volume of reducing gas during MBF operation low enough to insure effective zone 3 gas velocities. D.6 The inputs which can be regulated to maintain a maximum level of zone control when operating in the MBF mode are: the O₂ content in the blast to control the volume and temperature of the gas stream leaving zone 2; the volume and temperature of reducing gas injected through tuyere sets 2 and 3; and the amount of - coke charged (only enough to supply in zones 1 and 2 the carbon grate and the high (over 1000°C) temperature heat needed and not available from other sources). The endothermic inputs made through tuyere set 1 of such materials as oil, natural gas and steam will be reduced to zero but optionally, heat-supplying exothermic reacting powdered carbonaceous material such as coai can be used.

D.7 improved zone controlled blast furnaces being operated in a GBF mode can economically generate enough high quality reducing gas to make it practical and desirable to eliminate, "solution loss" in a MBF operation. The GBF mode efficiently utilizes a combination of the Boudouard and the water gas reactions and a high temperature, high 0₂ content (frequently near 50%) blast to consume a cheap solid carbonaceous burden in front of tuyere set 1, while maintaining the high flame temperature needed +o generate the high temperature heat employed in zone 1 and the bottom part of zone 2 to produce slag at desired temperatures and optionally a small volume of hot metal. An endothermic input through tuyere set 2 near the bottom of zone 3 can achieve zone control and regulate the temperature and composition of the specification MG (multipurpose gas) withdrawn through tuyere sets 3 and 4 at two different temperatures. A ratio of H₂:CO of at least about 1:6, particularly effective at MBF stack temperatures near 1000°C, will be maintained. The portions used as reducing gas can be blended as required for precision temperature control before being used, for example, by being injected into MBF tuyere sets 2 and 3. Solid carbon temperatures safely in excess of 1000°C and the presence of a molten basic slag will prevent the formation of CO₂ and H₂O and remove S. Zone control above tuyere set 4 in zone 3 can be achieved by regulating the amount of gas removed versus that allowed to ascend to the top thereby perpetuating the controlled pyrolysis activity that takes place to produce synprodsgas.

D.8 A high energy yield/ 1b. of carbon charged can be attained while consuming a minimum amount of high priced raw materials. Commercial O₂ is the exception but it is desirable to employ enough to reduce the gas flow out of MBF zone 2 into zone 3 so that high temperature heat generated In zone 1 is retained In zone 2; to increase the Btu content of the top MBF gas by decreasing the N₂ content of the reducing gas generated Internally and/or externally In a GBF operation; to maximize the volume of endothermic material that can be injected through GBF tuyere sets 1 and 2, and in this way to maximize the total volume of gas that can be produced per hour and per ton of carboniferous material charged; and to help regulate the temperature in GBF zones 1 and 2. D.9 Tuyere set 4 provides a way of doing accurate preventive-of-maIfunction control monitoring of zone 3. Samples taken through tuyere set 4 will advise whether the furnace's up moving gas stream is adequate to insure the desired result as It ascends the stack instead of furnishing late, inadequate information about something that previously happened. Such information is an Ideal input to a process control computer which can also receive inputs from the other gaseous input and output locations. Automatic computer controlled adjustments, made in the various tuyeres Inputs and the amounts withdrawn through tuyere outputs, in both MBFs and GBFs are sufficient to attain the high level of control sought because most of the operating conditions causing furnace malfunction, can be largely eliminated by employing basic improved zone control methods. D.10 Metallic oxide reduction in MBF practice can be improved by introducing reducing gas simultaneously into zone 3 both through the bottom and at the sides through tuyere sets 2 and 3. In this manner, the reducing gases flowing up are well distributed and channeling and the disproportionate high central flow characteristic of conventional practice (see U.S. Patent 3,588,067) are avoided. Reducing the coke consumed close to an absolute minimum (approximately 460 to 572 Ibs./THM) permits approximately double the volume of metal oxides to be maintained in the furnace at all times. D.11 Large gains can be made by departing further from the conventional practice of withdrawing materials only at the top and near the bottom of the furnace. In the GBF mode of operation it is desirable to vary the endothermic regulating input made through tuyere set 2 according to gases available, the volume of gas sought, the specification gas product being produced, and the manufacturing cost that will result. In MBF practice the ability to rem gases through tuyere sets 3 and 4 provides an opportunity to purge from the stack recycling vaporous undesirable metals such as alkali metals and zinc which cause problems such as reduced production due to impaired burden permeability, scaffolds and channeling, decreased coke strength, excessive refractory lining wear and premature failure, burden degredatlon, tuyere burning, a high hot metal sulfur content, excessive coke use, a decreased operating rate, and "solution loss" due to the catalytic effect of these metals in zone 3. U.S. Patents 12,329, 1,292,937, 1,466,625, 1,729,973, 2,365,868, 2,836,487, 2,877,086, and 3,188,201 all deal with methods of salvaging these materials but not with eliminating them as a cause of malfunction. Even relatively small amounts brought in with various burden materials tend to build up within the furnace and many conventional furnaces are dangerously close to a maximum allowable input. It has been necessary to stockpile millions of tons of valuable but contaminated materials. Three U.S. Patents, 1,431,877, 1,517,232 and 4,066,44 recognize this problem and propose chemical methods of removal. None of these methods are ful iy effective and they tend to have an adverse effect on manufacturing costs and hot metal quality (sulphur control ). The recycling alkali metals and zinc while they are in a vaporous form can be removed through tuyere sets 3 and 4 before concentrations are allowed to build up which endanger the operation. Reducing gas injected through tuyere sets 2 and 3 can be us&d to restore the heat lost to the burden during the purge cycler.

D.12 The top gas generated in MBF operations can become the valuable, relatively S free product, blast furnace utility gas (BFUG). Over one-half of it will be derived from the reducing gas produced in a GBF operation and injected. In the GBF, as the result of a high O₂ content blast, the MG produced and used as injected reducing gas will have a low N₂ content and a high Btu value. The gas volume moving up from in front of MBF tuyere set I will also have a reduced N₂ content because of the O₂ added to the blast, to largely prevent carrying high temperature heat out of zones 1 and 2 into zone 3. The blended gas stream resulting from these two practices will, in some cases be near a desired 155 Btu content which will give it a boiler efficiency equivalent to natural gas (See Exhibit 111) and the boiler stack exit gas will have an improved nitrous oxide content. As withdrawn, the Btu content will be between about 100 and 155 depending on the amount of O₂ employed in the MBF and GBF blasts. By blending It with a planned excess of MG withdrawn through GBF tuyere set 4, which will have a Btu range between 200 and 280, BFUG with a 8tu content between about 155 and the peak efficiency boiler fuel content of near about 250 Btu will be obtained.

D.13 In MBF operations, zones I and 2 are controlled largely independent of zone 3 to retain in zones 1 and 2 the heat above 1000°C. By increasing the O₂ in the blast, the N₂ and overall volume of gas/THM can be reduced enough so that the resulting decreased velocity plus an increase in heat above 1000°C per lb. of carbon oxidized will result in an optimum transfer of heat above 1000°C to the liquids and solids in zones 1 and 2. On-line control of MBF zones 1 and 2 can be accomplished entirely through tuyere set 1 by employing the information obtained from the gas samples withdrawn from tuyere set 4.

D.14 in MBF operation the amount of gas generated by consuming coke in zone 1 per ton of hot metal is minimized to increase the operating rate which is largely determined by the rate which is largely determined by the rate the generated gas can be pushed through the liquid versus gas counterflow portion of zone 2. Hot metal quality, uniformity and sulphur content, is dependent on avoiding a high volume and uneven flow through zone 2, as is the retention of an adequate amount of heat in zones 1 and 2. By limiting the total coke charged to that which must be consumed in zones 1 and 2 and injecting through tuyere sets 2 and 3 the major portion of the reducing gas that must be employed in zone 3 to eliminate "solution loss" and furnish a heat reserve, a minimum flow through zone 2 can be achieved.

D.15 improved zone controlled blast furnaces operated either the the MBF or GBF mode can produce valuable made to specification products for which there is a constant demand. In MBF operations this, abi I ity is almost entirely due to an increased level of temperature control in zone 2 and to a decrease in the N₂ content in the top gas. In GBF practice the character of the operation is entirely changed. In the main, low cost raw materials are employed and it will be practical to heed the advice of the Japanese nationwide task force dealing with the capture and disposal of ecologically undesirable process by-products - consume them in making needed products. Excess energy can be produced in generating specification gases, which can be employed to melt, pyrolyze (decompose by the presence of heat), crack, and convert large quantities of process gases and dusts without polluting and while replacing, in an economically attractive manner, a large amount of coke oven capacity which universally has been the source of many environmental complaints.

D.16 Mineral wool quality insulation product is conventionally made by remelti=g blast furnace slag in a cupola and then blowing or spinning the molten product into filaments. MBF or GBF practice can consistently produce slags with temperatures close to, but normally not below, 1600°C, which are adequate to produce mineral wool without remeiting. D.17 Precision cast synthetic igneous-rock castings impervious to fire, weather, molds and insect attack can be produced. Their use will not be limited because of relatively low tension limits and unlike reinforced cement the construction steps are few - many will be performed in blast furnaces while producing other products simultaneously. Molten slag can be withdrawn and be transported to where it will be poured into molds in much the same manner as molten metal is cast. Pipes, steel bar, wire or shaped metal can also be placed in the moid in such a manner that it will reinforce the poured sections, expedite connecting them to each other and to foundations and provide access space. Optimally the castings will be interlocking and connectable to other units by steel bars inserted through pipe reinforcing openings. To obtain certain specifications or prolong the pouring cycle the GBF product can be stored temporarily in fired holding and mixing units where additional materials can be added and stirred in. If desired, inorganic pigments can be added to color the product and additives, such as oxides, can be added to adjust the calcium, silicon, aluminum, magnesium and iron contents. The choice of appropriate additives is within the skill of the art. D.18 A molten blast furnace product can be produced which can be converted, without remeiting, into quality cement clinker. A zone controlled blast furnace operating in the GBF mode can make clinker using the basic slag employed to control the S content in MG and in any HM being produced. It is practical to bal ance the CaO, SIO₂, AI₂O₃, MgO and Fe₂O₃ slag components by charging appropriate calcareous materials such as limestone or other forms of CaCO₃, chalk, marl, cement rock, sea shells and marble so that basic eutectic slags are produced with compositions similar to those used in making all normal grades of cement and some with special qualities, which also have excellent desulphurlzation characteristics. Cement slags can be delivered to a large fired mixer. Samples taken will indicate the additions required which can be stirred into the molten bath ahead of a casting, cooling and/or granulation step employed to produce the cooled clinker then finely ground.

0.19 in GBF practice, no coke need be employed, there is no heavy downward flow of HM and much of the gas is produced by pyrolysis rather than by oxidation or cracking, avoiding a reforming step. The synprodsgas produced due to a high O₂ content in the blast is an excellent substitute for a large portion of the natural gas and petroleum presently consumed in producing a wide variety of products which include: sulphate of ammonia fertilizer, man made fibers such as nylon, plastics, insecticides, pharmaceuticals, paint, creosote, detergents, fungicides, explosives, solvents and other commercial chemicals. When the GBF charge contains amounts of oil shale and/or oil sand, synprodsgas will also contain a fraction suitable for refining into gasoline. Because of the charge options, the Btu content will vary from approximately 400 to 500.

D.20 A synthetic coke oven gas (SCOG) can be made from the GBF synprodsgas stream. The conversion process wilt be almost identical to that conventionally employed to produce coke oven gas from the gas fuel delivered from conventional by-product coke ovens. The principle components will be H₂, CO, CH₄ and other hydrocarbons and the Btu content will vary from about 425 to about 480 depending on the amount O₂ used in the GBF and the extent of the charge employed contains such raw materials as oil shale.

D.21 Steam can be generated from the sensible heat in top gas removed from zone controlled blast furnaces when operating in all modes by installing waste heat boilers or heat exchangers through which top gases will be withdrawn. When in the GBF mode, oil shale is charged the waste heat boiler wiII also be employed to condense the kerogen in the gas stream and remove it for separate processing.

D.22 Zone controlled blast furnaces can become the key units in diversfied manufacturing systems both large and small but each balanced to operate so that the most capital intensive portions will be able to consistently operate at near maximum capacity and continuously. A maximum amount of process by-products and low cost raw materials can consistently be consumed in an efficient cost reducing manner in the production of valuable products for which there is a relatively steady demand. Ecological problems inherent to the consumption of coal are decreased and the energy related portion of the cost of the products produced will be lower than can be attained employing conventional methods. The demand for HM is not normally constant. By employing multi-purpose furnaces capable of changing quickly from the MBF to the GBF mode of operation, when the need for HM decreases it is possible instead to manufacture specification gases and slags and convert them to electrical energy and long lived building materials such as synthetic igneous rock casting, cement and rock wool insulation for which the demand is expected to be more constant for many years. The GBF mode will have all the best features of their less highly developed prototype, the slagging-ash gas producer, plus those of the most highly developed modern blast furnaces and direct reduction units. They can employ the energy reserve they generate from the consumption of low cost solid carbonaceous materials in zone 1 to utilize the wide range of by-product and low cost raw materials introduced through tuyere sets 1 and 2 and at the top. When operated in the GBF mode to replace coke ovens, ecologically undesirable emissions will be reduced and more of the sulfur present in in raw materials, especially coal, will be safely entrapped in slag. Zone controlled blast furnace systems, in which hot metal is the major specification product, will contain at least two improved zone controlled blast furnaces, one operating in the GBF and the other in the MBF mode. To minimize material handling expense, certain other related manufactured units can be included, such as electrical power generation units, direct reduction units, processes consuming slag in a molten state, synprodsgas refinery processes, and oxygen plants. BOSP installations, by delivering their hot and uncleaned top gases to a zone controlled blast furnace system will be able to save much of the high capital, operating and maintenance costs involved in internal gas and dust disposition.

D.23 Even when oil or natural gas (NG) is relatively cheap and readily available, it will frequently be advantageous when operating DR (direct reduction) processes employing reducing gas generators or regenerators consuming oiI or NG, to obtain reducing gas from a blast furnace operating in the GBF mode. The gas delivered will be free of any significant content of CO₂, H₂O, or S and the delivery temperature can be precisely regulated within the range required. By recycling, without a cooling or cleaning step, the gas removed from the top into a GBF through tuyere sets 1 or 2, it will be possible to convert it back to reducing gas with a minimum use of a low cost fuel, in systems also containing an oxygen generation plant, waste N₂ wi 11 be available to employ in the cooling section of the DR stack furnace. Even when NG (natural gas) is being wasted it still may, in many cases, be more economic to consume low cost coal or lignite in the gas regeneration process and use the excess gas generated as a portion of the energy required to convert NG to LNG (liquid natural gas), a product welcome for highest and best use in many countries.

D.24 A blast furnace is an improved slagging-ash gas producer. An improved version of a blast furnace is one that is zone controlled. When the zone controlled blast furnace is operated in a GBF mode and four sets of tuyeres, two of which, tuyere set 1 and 2, are used to introduce inputs and two, sets 3 and 4, are used to remove a portion of the gas stream generated in the bosh in zones 1 and 2, the flexibility and efficiency gained is large. When provision is made to use maximum blast temperatures and a high added O₂ -content in the blast input through tuyere set 1 the practical operating rate becomes very high and the endothermic input allowable very large. By regulating the net endothermic input through tuyere sets 1 and 2 and also by injecting powdered carbonaceous-containing process dusts through tuyere set 1, a maximum carbon to gas yield is obtained. However, when the pyrolysis activities occurring in zone 3 are increased to a maximum point by charging through the top, materials such as oil shale, oil contaminated roll scale, solid industrial and. domestic wastes with a high carbonaceous or hydrocarbonaceous content, CO, H₂ and hydrocarbons are added to or kerogen contained in the gas stream removed from the top and carbon is added to the char consumed in front of tuyere set 1. By limiting the iron oxide charge to a small amount or none and removing a major portion of the gas formed through tuyere sets 3 and 4, stack permeability problems are minimized and the potential maximum operating rate increased.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be better understood by reference to the attached drawings. Figure I which is a schematic vertical section view of two zone controlled blast furnaces, one being operated in an MBF mode and the other in a GBF, and a portion of the major conduits, valves, and sampling stations that will be employed;

Figure 2 shows schematically a system suitable for manufacturing the range of specification products described; and Figure 3 is a boiler efficiency curve indicating the effect of Btu content on efficiency. These data were presented to EPRI Conference "Power Generation - Clean Fuels Today", April 1974 DETAILED DESCRIPTION OF THE INVENTION Improved zone controlled blast furnaces when operated in either the MBF mode 10 or GBF mode 56, desirably have four sets of tuyeres disposed around the periphery of the furnace, tuyere sets 1, 21 and 43 at the bottom of the bosh, tuyere sets 2, 19 and 45, located just below the mantle 17 and 50, tuyere sets 3, 16, and 47, just above the mantle, tuyere sets 4, 13 and 49, located above set 3 but near the bottom of zone 3. In both modes solid material that are not in a powdered form, are charged at the top in a conventional manner except in the MBF the coke charge is only sufficient to provide the coke grate and the high temperature heat above 1000°C not available from other sources (460 to 570 Ibs./THM) and the metal bearing charge is approximately twice the conventional amount of metallic oxide/T coke. in the GBF mode, the conventional coke charge is replaced by low cost coal, lignite or other solid carbonaceous material such as industrial or domestic wastes. The metal bearing charge is small and flux materials, predominately calcareous in nature, are included as required to produce both an adequate desulphurizing slag and cast slags suitable for producing specification products including cement clinker and synthetic-igneous-rock castings. Optionally kerogen and hydrocarbon-bearing materials such as oil shale are included in the charge. in the MBF mode, powdered carbonaceous materials, may be injected through system 24 and in the GBF at 41. The powdered material, 77, in the MBF can be coal, powdered coke breeze, char or other exothermic reacting material containing mainly amount of powdered carbonaceous material injected through the MBF injection system 24 is sufficient when combusted by an O₂ enriched blast originated in power house 25 and delivered through conduit 73, to provide enough high temperature heat to make up any difference between the high temperature heat generated by oxidizing with an O₂ high temperature blast a minimum amount of coke charged to provide an adequate grate and the additional high temperature heat requirements in zones 1 and 2 needed to produce a uniformly high quality adequately desulphurized HM. In the GBF the dust charge may be any combination of finely divided process dust, 37, such as blast furnace flue dust, BOSP 34, dust transferred through conduit 35 to BOSP gas storage vessel 36, which have either a high Fe or C content. The hot blast heated in MBF and GBF stoves 33 and 66, conducted through conduits 29 and 71, injected through bustle pipe 20 and tuyere set 21 in the MBF and bustle pipe 42 and tuyere set

43 in the GBF is O₂ enriched in both cases, but to a varying degree, in the MBF enough O₂ is used in the blast to reduce the volume of the gas generated in zone 1 enough to enable it to transmit its heat above 1000°C to the burden before leaving zone 2. In the GBF the O₂ content in the blast introduced into tuyere set 43 through bustle pipe 42 is sufficient to attain a desired flame temperature while converting maximum amounts of primary tuyere injected H₂O and/or (XL, a high Btu/minute, production rate and Btu/of content. Enough reducing gas MG is produced in the GBF 56 and withdrawn through tuyere sets 47 and 49 and thence to bustle pipes

46 and 48 and brought into the MBF through bustle pipes 14 and 18 and tuyere sets 16 and 19 to create a heat reserve just under 1000°C at the bottom of zone 3 and a chemical reserve throughout the length of zone 3 in which a continuously reducing atmosphere is maintained that is adequate to insure reduction of a well prepared iron oxide burden before it leaves the zone, without incurring any significant "solution loss". Over one-half of the gas employed in MBF zone 3 is produced in a GBF and injected as described. The temperature and composition of MG used as reducing gas is regulated by endothermic gaseous inputs made through GBF tuyere sets 43 and 45 before it is withdrawn through tuyere sets

47 and 49. The extent and character of the endothermic reactions in front of tuyere set 45 is on-line regulated, on the basis of samples taken at tuyere set 46, sample station 51, to insure that all materials injected are being converted to a gas composed of CO, H₂ and N₂, that the H₂:CO ratio is at least about 1:6, and that the desired gas stream temperature of close to 1000°C is being obtained.

The gaseous inputs made through GBF bustle pipe 42 and tuyere set 43 is regulated so as to utilize the Boudouard reaction to the maximum economic degree. The amount of CO₂ and H₂O containing gas injected there is regulated to attain a desired flame temperature at an economic usage of O₂. The economic level ofO₂ will depend on the specified Btu content of the BFUG and MG gas being delivered and the GBF gas production rate required. When, for example, approximately 50% of the O₂ in the hot blast used in the GBF is from commercial O₂, the amount of MG which must be blended with MBF top gas to produce a BFUG with a 155

Btu content will be relatively small. The top gas leaving MBF's through conduit 7 will normally be converted to BFUG by the addition of a measured amount of MG made through conduit 57 ahead of waste heat boiler 2. An alternate use will be to inject some portion into the GBF through conduit 31 injection system 41 ahead of tuyere set 43 or into bustle pipe 44 thence to tuyere set 45.

MG used as reducing gas is withdrawn through tuyere set 47, at close to 1000°C. That withdrawn through 49 is at a lower temperature and may be used also for a variety of other purposes. The stream going into tuyere sets 16 and 19 through bustle pipes 15 and 18 can be independently regulated by varying the amount obtained from each set of GBF tuyeres.

Quartered gas samples are withdrawn through MBF tuyere set 13 and GBF tuyere set 49 via bustle pipes 12 and 48 and the analysis results furnished a process control computer. Adjustments are made immediately preferably by automated means.

Zone control in GBF zone 3, because the amount of MG delivered to MBF's or DR is determined by their requirements, will be attained by regulating the volume of MG withdrawn through tuyere set 49 into bustle pipe 48 thence by conduit 61 to GBF conventional cleaning. system 60 then to MG gas storage 62 and the amount sent up through GBF zone 3. The temperature of the rising gas stream is measured at sample station 52 of gas withdrawn at tuyere 49 and the top at sample station 55 to make certain that it is being kept high enough to insure pyrolysis of the coal or other hydrocarbon containing material charged, before the burden descends to tuyere 49 level.

Because of improved process control the HM withdrawn at MBF notch 23 and GBF notch 39 will normally be delivered direct to the BOSP 34 without a costly outside the furnace desulphurlzatlon step.

Slag is removed through MBF notch 22 and GBF notch 40. The MBF top gas withdrawn at 7 will, as made (low N reducing gas used), be BFUG or become BFUG by blending with enough MG delivered through conduit 47 to bring its Btu content up to at least 155.

Synprodsgas is withdrawn at the top of the GBF through conduit 53. Its Btu content will vary, according to the hydrocarbon containing materials other than coal or lignite, charged at the top, from about 400 to 500. It goes to synprodsgas refinery 76 through conduit 53, sampling station 55, GBF waste heat boiler 59 and conduit 58. When oil shale is charged the waste heat boiler will be used to condense in addition to tar, kerogen. These will be withdrawn at 79 and 80. A major product usually separated will be. SCOG with a Btu content of approximately 425 to 480.

Process control computer complexes optionally controlling zone controlled blast furnaces by automated means, can receive information from a variety of sources but the most important will include: information obtained from on-line samples taken at GBF sample station 51 of gas withdrawn from bustle pipe 46 and the temperature of the gas at sample station 52 of gas withdrawn from bustle pipe 48; information concerning gas composition, temperature and pressure obtained from on-line MBF samples taken at station 14 from gas withdrawn from bustle pipe 12 and at sample station 8 of gas withdrawn from the top of MBF 10; the gas temperature, flow rate and pressure taken of samples from station 30 ahead of tuyere set 19 and station 26 ahead of tuyere set 16; information obtained during purge cycles from the sample: station 9 ahead of waste heat boiler 2 and the Zn, K and Na content determined; the measured content and temperature of the synprodsgas stream leaving the GBF through conduit 53 and samples at station 55 will be analyzed for composition and temperature; the temperature and composition of the uncleaned MG delivered to DR 69 through conduit 68 will be obtained from samples taken at 67; the various gaseous endothermic inputs (38) injected into GBF tuyere sets 43 and 45 through injection system 41 and bustle pipe 44 will be sampled at stations 78 and 79 and information concerning composition and temperature input to the control computer; and the temperature and Btu content taken at sample station 63 of the MG gas from storage stream delivered through conduit 64 to electric power generation 32 and other MG users.

The process control computer can employ the on-line information obtained to adjust the various gas flows as required to maintain a zone controlled operation in both MBF's and GBF's in the system and make gaseous specification product deliveries to the other operating units in the system and to outside users through BFUG storage 4 and MG storage 62. The methods of manipulating the gas flows in the manner required will be similar to that applied on many industrial units other than blast furnaces i.e., DR installations, petroleum refineries, petrochemical plants, etc.

When tests, MBF malfunction, or past experience indicate a purge cycle is needed the valves in conduit 27 controlling the delivery of reducing gas to bustle pipe 15 are closed, the total flow reduced and delivered to bustle pipe 18. Simultaneously the blast is proportionately reduced. The valves between tuyere set 16 and conduit 11 are opened to divert the much reduced flow containing Zn and Na in vapor form, to waste heat boiler 2 and conventional wet cleaning system, 3. Effluent, from the cleaning system can be diverted to a Doer thickner. After the burden has descended a measured amount, the valve between tuyere set 16, bustle pipe 15, and conduit 11 is closed. The blast and other inputs through MBF tuyere set 21 are further reduced and the reducing gas inputs through tuyere sets 16 and 19 are resumed, by opening the valves to conduits 27 and 28 Jong enough to furnish the burden above tuyere set 16 the heat lost during the first phase of the purge. When this has been accomplished the inputs through 16 and 19 and the blast into 21 again reduced until the burden has descended a measured number of feet. During this period the purge flow leaving through tuyere set 13, bustle pipe 12 and conduit ii will contain a major portion of any K and KCN that has been recycling. After the valve from 12 into conduit 11 is closed at the end of the purge cycle the blast through tuyere set 21 is again largely withdrawn until the reducing gas injected through 16 and 19 at a normal or temporarily increased volume has furnished enough heat to bring the heat reserve area in zone 3 up to close to 1000°C. At the time the normal input through tuyere set 21 is resumed completing the purge cycle and the effluent from 3 will be returned to its normal flow pattern.

Slag removed from MBF notch 22 is delivered to an MBF slag processing location 1. Slag removed from GBF slag notch 40 is delivered at near the temperature withdrawn to a slag products manufacturing area 75, suitably equipped to manufacture cement clinker and pour synthetic-igneous-rock castings. it can be held at temperature in a slag mixer, 74, adjoining storage capacity for finely ground materials used in the manufacture of cement clinker. in some instances MBF slag will also be delivered to slag mixer 74, The additions required to produce the ordered cement or castings specifications can be added before the pouring, cooling and/or granulation manufacturing steps are taken.

Steam from the MBF and GBF waste heat boilers 2 and 59 is delivered through conduits 6 and 72 to the electrical power generation unit 32. BFUG can also be delivered there through conduit 5 and/or MG through conduit 64. These gases are acceptably free from S and particulate matter. The flow of MG going to DR units is temperature regulated by blending gas removed at GBF tuyere sets 49 and 47 to the extent required to obtain a required injection temperature. DR exit gas, 70 is recycled to GBF, 56, through conduit 41.

Since variations of this invention will be apparent to those skilled in the art, it is intended that this invention be limited only by the scope of the claims.

Claims (11)

1. CLA1MS 1. A method of controlling a molten iron-producing blast furnace having three zones, zone 1 being in front of the primary tuyeres, zone 2 being the balance of the bosh extending from the crucible to the mantle, and zone 3 extending above the mantle, and wherein a charge is introduced into the top of the furnace, is preheated, iron oxides are reduced to iron as the charge moves downwardly through zone 3, and is melted in zone 2, which method comprises:

   (a) introducing into the top of the furnace a charge containing a iron oxide, flux and from about 460 to about 570 pounds of coke per ton of hot metal, said coke providing a carbonaceous grate and the major portion of the fuel for high temperature heat above about 1000°C in zones 1 and 2;

   (b) burning coke in said charge in zone 1 with oxygen-enriched air to produce a high temperature gas to mel t i ron and s l ag in zone and to prov i de an upward l y moving gas stream whose temperature is reduced to about 1000°C at about the top of zone 2;

   (c) introducing a reducing gas at a temperature of about 1000°C sthrbogh tuyeres near the mantle at the bottom of zone 3, said gas containing CO, H₂ and N₂ and being substantially free of CO₂, H₂O and sulfur, said gas providing at least about one-half of the CO and H₂ that passes upwardly into zone 3 to reduce the iron oxide to iron;

   (d) controlling the introduction of said reducing gas to maintain a H₂:CO ratio of at least about 1:6 in said upwardly moving gas near the bottom of zone 3 and to provide sufficient CO to substantially avoid solution loss of coke in zone 3;

   (e) withdrawing molten iron and molten slag from near the bottom of the furnace; and

   (f) withdrawing gas from the top of said furnace having a heat content of from about 100 to about 155 Btu per cubic foot.
2. 2. The method of Claim 1 wherein the blast furnace has two sets of tuyeres at different levels near the bottom of zone 3, and the upper of said two sets of tuyeres is used to sample gases for control of furnace combustion in zone 1 and introduction of reducing gases into the furnace.
3. 3. The method of Claim 1 or 2 wherein gases are periodically removed through tuyeres in the lower portion of zone 3 in order to purge undesirable vaporous metai from the furnace.
4. 4. A method of controlling a reducing gas producing blast furnace having three zones, zone 1 being in front of the primary tuyeres, zone 2 being the balance of the bosh extending from the crucible to the mantle, and zone 3 extending above the mantle, and wherein a charge is introduced into the top of the furnace, is preheated as it moves downwardly through zone 3 and is melted in zone 2, which method comprises:

   (a) introducing a charge containing solid carbonaceous matter and slag producing material near the top of the furnace;

   (b) burning the carbonaceous material in said charge in zone i to melt slag in zone 2 and to provide heat for the endothermic reactions of step (c);

   (c) introducing a CO₂ and H₂O containing gas into the furnace through tuyeres below the mantle to endothermically react with carbon at a temperature over about 1000°C to produce CO and H₂;

   (d) maintaining the temperature of the gas near the bottom of zone 3 at about 1000°C;

   (e) withdrawing gas from tuyeres located near the bottom of zone 3 and above the mantle, said gas having a Btu content per cubic foot content of at least about 200, containing CO,

   H₂ and N₂ and being substantially free of CO₂, H₂0 and sulfur;

   (f) removing molten metal and molten slag having a temperature of at least about 1600°C from near the bottom of the furnace; and

   (g) removing a gas from near the top of said furnace, said gas containing compounds produced by pyro lysis and vaporization in zone 3 and selected from the group consisting of hydrocarbons, CO, CO₂, H₂, H₂O, N₂ and sulfur compounds.
5. 5. The method of Claim 4 wherein said blast furnace has two sets of tuyeres at different levels near the bottom of zone 3, and reducing gas at different temperatures is withdrawn from each set of tuyeres near the bottom of zone 3.
6. 6. The method of Claim 4 or 5 wherein a solid carbonatioπ other than coke such as coal is charged to the top of said blast furnace.
7. 7. The method of Claim 4, 5, or 6, wherein the charge to the furnace includes a balance of slag forming materials suitable for forming a slag effective in removing sulfur and in forming the equivalent of cement clinker when withdrawn from said furnace and any amount of powdered material required to meet specifications is added to the molten slag before it is cooled, granulated or pulverized.
8. 8. The method of any one of Claims 4, 5 or 6, wherein molten slag is withdrawn from said furnace and formed into castings,
9. 9. The method of any one of Claims 4 through 8 wherein oil shale is included in the solid charge and vaporous kerogen is withdrawn from the top of the blast furnace along with top gas.
10. 10. A method of operating blast furnaces which comprises:
11. 1. controlling molten iron-producing blast furnace having three zones, zone 1 being in front of the primary tuyeres, zone 2 being the balance of the bosh extending from the crucible to the mantle, and zone 3 extending above the mantle, and wherein a charge is introduced into the top of the furnace, is preheated, iron oxides are reduced to iron as the charge moves downwardly through zone 3 and is melted in zone 2, which method comprises:

    (a) introducing info the top of the furnace a charge containing iron oxide, flux and from about 460 to about 570 pounds of coke per ton of hot metal, said coke providing a carbonaceous grate and the major portion of the fuel for high temperature heat above about 1000°C in zones 1 and 2;

    (b) burning coke in said charge in zone 1 with oxygen-enriched air to produce a high temperature gas to melt iron and slag in zone 2 and to provide an upwardly moving gas stream whose temperature is reduced to about 1000°C at about the top of zone 2;

    (c) introducing a reducing gas at a temperature of about 1000°C through tuyeres near the mantle at the bottom of zone 3, said gas containing CO, H₂ and N₂ and being substantially free of CO₂, H₂O and sulfur, said gas providing at least about one-half of the CO and H₂ that passes upwardly into zone 3 to reduce the iron oxide to iron;

    (d) controlling the introduction of said reducing gas to maintain a H₂:CO ratio of at least 1:6 in said upwardly moving gas bear the bottom of zone 3 and to provide sufficient CO to substantially avoid solution loss of coke in zone 3;

    (e) withdrawing molten iron and molten slag from near the bottom of the furnace; and

    (f) withdrawing gas from the top of said furnace having a heat content of from about 100 to about 155 Btu per cubic foot; and which further comprises: ii. controlling a reducing gas producing blast furnace having three zones, zone 1 being in front of the primary tuyeres, zone 2 being the balance of the bosh extending from the crucible to the mantle, and zone 3 extending above the mantle, and wherein a charge is introduced into the top of the furnace, is preheated as it moves downwardly through zone 3 and is melted in zone 2, which method comprises:

    (a) introducing a charge containing solid carbonaceous matter and slag producing material near the top of the furnace;

    (b) burning the carbonaceous material in said charge in zone 1 to melt slag in zone 2 and provide heat for the endothermic reactions of step (c);

    (c) introducing a CO₂ and H₂O containing gas into the furnace through tuyeres below the mantle to endothermically react with carbon at a temperature over about 1000°C to produce CO and H₂;

    (d) maintaining the temperature of the gas near the bottom of zone 3 at about 1000°C;

    (e) withdrawing gas from tuyeres located near the bottom of zone 3 and above the mantle, said gas having Btu content per cubic foot content of at least about 200, containing CO, H₂ and N₂ and being substantially free of CO₂, H₂O and sulfur and introducing at least a portion of said gas in step 1(c) above;

    (f) removing molten slag having a temperature of at least about i600°C from near the bottom of the furnace; and

    (g) removing a gas from near the top of said furnace, said gas containing components selected from the group consisting of hydrocarbons volatilized and pyrolysed in zone 3, CO, CO₂, H₂, H₂O, N and sulfur compounds. ii. A multiproduct manufacturing system comprising: (a) two blast furnaces, each of said blast furnaces having three zones, zone 1 wherein primary combustion occurs, zone 2 being the balance of the bosh extending from the crucible to the mantle, and zone 3 extending above the mantle, and each of said blast furnaces having a primary set of tuyeres for zone 1, a set of tuyeres located near the top of zone 2 and two sets of tuyeres located above the mantle and at the lower portion of zone 3; and

    (b) conduit means connecting the two sets of tuyeres near the bottom of zone 3 of said second furnace with at least one set of the tuyeres near the bottom of zone 3 of said first furnace, whereby reducing gases generated in said second furnace can be introduced into zone 3 of said first furnace.